Windshield repair assembly

ABSTRACT

A repair assembly for the in-place repairing of windshields and the method for using such assembly, wherein a repair material injected into the windshield break area by a syringe and needle is forced into the windshield break through the repair assembly secured and sealed to the windshield by first applying stepped increments of measured vacuum levels and visually monitoring the windshield break area, and second applying positive pressure to the windshield break. An ultraviolet light source completes the repair by expediting hardening of the repair material within the windshield break to prevent refraction of light at the windshield break.

This application is a continuation-in-part of application Ser. No.569,753, filed Jan. 10, 1984, which has matured into U.S. Pat. No.4,597,727, which in turn is a continuation-in-part of application Ser.No. 470,440, filed Feb. 28, 1983, now abandoned.

FIELD OF THE INVENTION

This invention relates to a repair assembly for the in-place repairingof automobile windshields.

DESCRIPTION OF THE PRIOR ART

In U.S. Pat. No. 3,562,366 to Sohl and U.S. Pat. No. 3,765,975 toHollingsworth, windshield cracks were repaired by using ultrasonicvibrations or mechanical force to cause a polymer solution to fill upthe windshield crack. Also described in the Hollingsworth patent is theuse of alternate negative and positive pressure cycles in somesituations. Another method, U.S. Pat. No. 3,993,520 to Werner, et al.,expedited filling of the windshield crack by outgassing the polymersolution prior to injection then applying positive and negative pressurecycles. It has been a problem in the use of negative and positivepressure cycles to designate accurate pressure levels and timessufficient to insure complete filling of the windshield crack withpolymer solution or other repair materials so as to repair thewindshield and to monitor progress of the repair so as to insureexhaustion of air from the windshield break cavity, thereby allowingcomplete filling by the repair material

SUMMARY OF THE INVENTION

The present invention is summarized in that a kit and method forrepairing windshield breaks includes positioning a repair assembly overthe windshield break; securing the repair assembly on the windshield;placing a screw having a lengthwise cylindrical opening and a gasket atone end into the repair assembly over the windshield break with thegasket end located on the windshield; turning the screw down on thewindshield until the gasket at the end of the screw forms a generallyfluid-tight seal with the windshield; injecting a repair material intothe windshield break area through the screw; creating a vacuum in therange of 10-20 inches of mercury over the windshield break for about 3-7minutes; increasing the vacuum over the windshield break to within therange of 15-25 inches of mercury and maintaining the increased vacuumfor about 3-7 minutes; further increasing the vacuum over the windshieldbreak to within the range of 20-30 inches of mercury and maintaining thefurther increased vacuum for about 3-7 minutes, thereby forcing air outof the windshield break; and creating a positive pressure over thewindshield break for about 3-10 minutes, thereby forcing the repairmaterial into the windshield break.

It is an object of the present invention to provide a reusable kit andsimple method for repairing windshield breaks.

It is a further object to provide a means to obtain maximum visualmonitoring of the windshield repair, including formation of a generallyfluid-tight seal of the apparatus on the windshield and exhaustion ofair from the windshield break area.

It is a still further object of the present invention to designateaccurate pressure levels and times sufficient to insure complete fillingof the windshield break with a repair material.

Other objects, advantages and features of the present invention willbecome apparent from the following specification when taken intoconjunction with the accompanying drawings

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a kit for repairing a windshield with abulls-eye crack.

FIG. 2 is a schematic representation of the repair assembly portion ofthe windshield repair kit of FIG. 1 applied to a windshield with abulls-eye crack.

FIG. 3 is a close-up, cross-sectional view of the repair assemblyapplied to a windshield with a bulls-eye crack.

FIG. 4 is a plan view of an alternate embodiment of a kit for repairingwindshields with a bulls-eye crack.

FIG. 5 is a schematic representation of a first alternative embodimentof a windshield repair assembly and a mirror as applied to a windshieldwith a bulls-eye crack.

FIG. 6 is a schematic representation of a second alternative embodimentof a windshield repair assembly as applied to a windshield with abulls-eye crack.

FIG. 7 is a section view taken along section line 7--7 of FIG. 6.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates the windshield repair kit 1 which is used to repairwindshields according to the present method.

Referring to FIG. 2, the windshield 10 to be repaired comprises aplastic layer 12 sandwiched between an inner glass layer 14 and outerglass layer 16. As is typical of bulls-eye cracks in safety glasswindshields, the outer glass layer 16 has a cone-shaped cavity 18containing a conical glass segment 20. The area of the cavity 18 is tobe filled in with a repair material which will harden so as to retainthe conical glass segment 20 in place and prevent refraction of light atthe cavity 18. A repair assembly 22 is shown mounted in position on thewindshield 10 so as to commence repair of the windshield break indicatedby the cavity 18.

The components required to repair a pockmarked windshield are suppliedin the form of a kit 1, as illustrated in FIG. 1. A repair assembly 22is shown which is comprised of a base 24 which has an opening, notshown, a neck 28 attached to the base 24 having a circular opening 30,shown in FIG. 1, a suction cup 32 attached to one side of the base 24,an arm 34 attached to the suction cup 32 and projecting perpendicular tothe base 24 through the base opening and a clamp 36 attached to the arm34 and adapted to move so as to pull the arm 34 outward. A mirror 37 isprovided which is adapted to be placed against the windshield 10 on theside of the windshield opposite the repair assembly 22. Also shown is ascrew 38 which is adapted to be positioned in the circular opening 30 ofthe repair assembly neck 28. The screw 38 has a lengthwise cylindricalopening 40 and gasket, such as an o-ring 42, attached to the end of thescrew 3S opposite the head of the screw 38. A tube 44 is provided, whichtube 44 is adapted to be positioned in the end of the screw cylindricalopening 40 opposite the o-ring 42.

A repair material 46 is included which is adapted to fill in thecone-shaped cavity 18 surrounding the conical glass segment 20, shown inFIG. 2. The kit includes a repair material applicator adapted to fitinto the cylindrical opening 40 of the screw 38. The repair materialapplicator shown in FIG. 2 is a syringe 48 which is adapted to fill upwith the repair material 46. Also provided is a needle 50 which isadapted to attach to the syringe 48 and to be inserted in the tube 44.Alternatively, the repair material applicator could be a disposableplastic container, with or without a premeasured amount of repairmaterial 46, which container would have a snoutlike dispenser adapted tofit into the cylindrical opening 40 or tube 44. Any device which candeliver selected amounts of repair material 46 within the cylindricalscrew 40 to the windshield break area 18 would be suitable for use as arepair material applicator.

A vacuum pump 52 is shown which is adapted to attach by means of a hose53 to the screw 38 or, alternatively, to the tube 44. A gauge 54measures the level of vacuum supplied by the pump. Also shown is apositive pressure applicator 56 adapted to be inserted in the screw 38or, alternatively, in the tube 44. The positive pressure applicator 56in one embodiment is a syringe which has a notched handle 58 which notchcan be engaged by a clip 60 located on the pressure syringe. Instead ofa pressure syringe an air pump (not shown) with a conventional checkvalve apparatus can be used as a positive pressure applicator.Alternatively, a single apparatus capable both of pulling a vacuum andapplying pressure can be used in place of the vacuum pump 52 and thepositive pressure applicator 56; this would be advantageous because onlyone attachment to the screw 38 or the tube 44 need be made.

In case a repair material is selected which must be treated withultraviolet light before it will harden within the windshield crack, anultraviolet light source 62 is provided which is adapted to provideultraviolet light to the area surrounding the bulls-eye crack in thewindshield once the repair material has been inserted in the bulls-eyecrack.

FIG. 4 illustrates an alternative embodiment, kit 2. The parts of kit 2which are identical with kit 1 are numbered accordingly. The parts whichare different in kit 2 are numbered in a 100-series.

In kit 2 the mirror 37 is mounted on a support frame 166 which issecured on the windshield by means of a pair of suction cups 168. Thescrew 38 adapted to be positioned in the circular opening 30 of therepair assembly neck 28 has a quad ring 142 for a gasket, instead of theo-ring 42 shown in FIG. 1. The quad ring 142 provides a betterlow-pressure seal in both negative and positive pressure ranges which isimportant for star breaks which can be increased by excess pressure.

A tube 144 is provided which is adapted to be positioned in the end ofthe screw cylindrical opening 40. The tube 144 is made out of Delrin, asynthetic material which doesn't absorb moisture; a quick-connectfitting (not shown) is mounted at the end of the Delrin tube 144.

A unitary fluid pressure pump 152 is provided, which takes the place ofthe vacuum pump 52 and positive pressure applicator 56 illustrated inFIG. 1. The fluid pressure pump 152 has a two-way valve 170, manipulatedby caps 172 and 176, which valve 170 controls whether the pump 152 drawsa negative pressure or a positive pressure. Two check valves 169 and 171are connected by means of tubing 173 to the two-way valve 170. The twocheck valves 169 and 171 are also connected by means of fixtures 177 and179 to a piston cylinder 181 containing a piston 174, a tube 178 similarto the tube 144 is connected to valve 170. A quick-connect fitting (notshown) is mounted at the end of tube l78. A gauge 154 is mounted on thehousing of tube 178 which gauge 154 measures negative pressure in inchesof mercury and positive pressure in pounds per square inch.

If cap 172 of the two-way valve 170 is pulled out, the pump suppliesnegative pressure when the piston 174 is pulled out because air is drawndown the tube 178, through valve 170, tubing 173, and check valve 169into fixture 177 and piston cylinder 181. If cap 176 of the two-wayvalve 170 is pulled out, as is the case in FIG. 4, the pump suppliespositive pressure when the piston 174 is pushed in because air is forcedup through piston cylinder 181, fixture 179, check valve 171, tubing175, valve 170, and into the tube 178. Vents in valve 170, not shown,release excess air out the pressure side during the vacuum phase whenthe piston 174 is pushed in, and relieve the vacuum from the vacuum sideduring the positive pressure phase when the piston 174 is pulled out.

The hose 53 is provided with a pair of fastening clips 180, one at eachend. Each clip 180 fastens onto the quick-connect fittings of tubes 144and 178 to provide fluid-tight seals.

FIG. 5 illustrates a first preferred embodiment of a repair assembly 22and mirror 37 to be used in kits 1 or 2. The parts of the repairassembly 22 which are identical with the repair assembly 22 shown inFIGS. 1-4 are numbered accordingly. The parts which are different arenumbered in a 200-series.

Referring to FIG. 5, the first preferred repair assembly 22 has asuction cup base 221 which can easily be purchased. The suction cup base221 shown in FIG. 5 has a base 224 with a plurality of openings, asuction cup 232 attached to the windshield side of the base 224 whichsuction cup 232 has at least one handle 243 for ease in removing therepair assembly 22 from the surface of the windshield 10, and an arm 234attached to the suction cup 232 and projecting out through a sidewaysopening of the base 224, which arm 234 is adapted to be movable in andout from the base 224 so as to exhaust air out from the suction cup 232,thereby forcing the edges of the suction cup 232 to adhere to thewindshield 10.

The repair assembly 22 also has a neck 228 having a first section 229with a circular opening 230 in it adapted to receive the screw 38, andalso having a second section 231 formed at an angle to the first section229 which second section 231 has a lengthwise slit 233. A first pivotalconnector 235 located on top of the base 224 of the suction cup base 221connects the suction cup base 221 to the lengthwise slit 233 of thesecond section 231 of the neck 228.

Associated with the first pivotal connector 235 is a first adjustingscrew 237 which serves as a first adjusting means and which can be movedso as to allow the neck 228 to rotate around the suction cup base 221 bymeans of the first pivotal connector 235. The first adjusting screw 237can be turned one direction in order to loosen the first pivotalconnector 235 so as to allow the neck 228 to be moved into approximateposition (with respect to the windshield break area 18) by rotationaround the suction cup base 221, then the first adjusting screw 237 canbe turned the opposite direction so as to tighten the first pivotalconnector 235 so that the neck 228 will no longer be free to rotatearound the suction cup base 221. Other first adjusting means such asclamps or the equivalent can be used in place of the first adjustingscrew 237.

A second pivotal connector 239 extends out from the first pivotalconnector 235 through the lengthwise slit 233 of the second section 231of the neck 228. Associated with the second pivotal connector 239 is asecond adjusting screw 241 which serves as a second adjusting means andwhich can be moved so as to allow the second pivotal connector 239 tomove the length of the lengthwise slit 233, and also to allow the neck228 to pivot around the second pivotal connector 239. The secondadjusting screw 241 is analogous to the first adjusting screw 237.

The second adjusting screw 241 can be turned one direction in order toloosen the second pivotal connector 239 to move the length of thelengthwise slit 233, or to allow the neck 228 to pivot around the secondpivotal connector 239 thereby moving the screw 38, located in thecylindrical opening 230 of the neck 228, directly into position over thewindshield break area 18; then the second adjusting screw 241 can beturned the opposite direction so as to tighten the second pivotalconnector 239 so that the second pivotal connector 239 will no longer befree to move the length of the lengthwise slit 233, and the neck 228will no longer be able to pivot around the second pivotal connector 239;the screw 38 will thus remain securely in position over the windshieldbreak area 18. As with the first adjusting means, other second adjustingmeans such as clamps or the equivalent can be used in place of thesecond adjusting screw 241.

The adjustments afforded by the second pivotal connector 239 areillustrated in FIG. 5 by comparing the bold-line view to the phantomview. In both views the suction cup base 221 has been placed on arelatively flat portion of windshield. In the bold-line view, thewindshield break area 18 is in a curved section of the windshield 10rather than in a flat section of the windshield 10 coplanar with thesuction cup base 221. Therefore, the neck 228 has been positioned bymeans of the second pivotal connector 239 so that the screw 38 can belocated perpendicular to the windshield break area 18, even though theplane of the suction cup base 221 is not perpendicular to the windshieldbreak area 18. In the phantom view, the suction cup base 221 is in thesame position; however, the windshield break area 18 is farther from thesuction cup base 221 and in a flat section of the windshield coplanarwith the suction cup base 221. Therefore, the second pivotal connector239 has been moved with the second adjusting screw 241 so that incomparison to the bold-line view, the second pivotal connector 239 isclose to the end of the lengthwise slit and the neck 228 has beenpivoted around the second pivotal connector 239, in an upward directionfrom that shown in the bold-line view.

As shown in FIG. 5, the mirror 37 is mounted inside a suction cup 268which suction cup 268 is adapted to adhere to the windshield upon theapplication of hand pressure.

FIGS. 6 and 7 illustrates a second preferred embodiment of a repairassembly 22 to be used in kits 1 or 2. The parts of the repair assembly22 in FIG. 6 which are identical with the repair assembly 22 shown inFIGS. 1-4 are numbered accordingly and those parts which differ arenumbered in a 300-series.

Referring to FIGS. 6 and 7, the second preferred repair assembly 22 issimilar to the first preferred repair assembly in that it includes asuction cup base 321 with a base 324 having a plurality of openings anda suction cup 332 attached to the windshield side of the base 324, aneck 328 which has a first section 329 with a circular opening 330 toreceive a screw 38 and a second section 331 formed at an angle to thefirst section 329, the second section 331 having a lengthwise slit 333.The repair assembly also includes the screw 38 which is inserted intothe circular opening 330. However, the suction cup base 321 of thesecond preferred embodiment further includes a leg 390 which extends outin a sideward direction opposite the neck 328 and has a small opening391 therein to receive a lifting screw 392, and the repair assembly 22further includes the lifting screw 392 inserted into the small opening391. The second preferred repair assembly 22 also has a vacuum pump 395attached to the suction cup 332 which projects out through a sidewaysopening of the base 324. The vacuum pump 395 has an arm 334 adapted tobe moved in and out from the base 324 to exhaust air out from thesuction cup 332 so that the edges of the suction cup 332 adhere to thewindshield 10. The second preferred repair assembly 22 has no partsanalogous to the first pivotal connection 235 or to the first adjustingscrew 237 in the first preferred repair assembly 22. The secondpreferred repair assembly 22 does have a pivotal connecting means 339for pivotally connecting the neck 328 to the suction cup base 321through the lengthwise slit 333 in the second section 331 of the neck328. This pivotal connecting means 339 is analogous to the secondpivotal connector 239 in the first preferred repair assembly 22. Anadjusting and locking means 396 for adjusting and locking the positionof the neck 328 in relationship to the suction cup base 321 is analogousto the second adjusting screw 241. The suction cup base 321 includes afirst yoke arm 397 and a second yoke arm 398 extending therefrom to holdthe pivotal connecting means 339, and the adjusting and locking means396.

In the second preferred repair assembly 22, the pivotal connecting means339 is a shaft 399 of an adjusting screw 341, the adjusting screw 341having in addition to the shaft 399, a threaded end 380, a handle 381and a flange 375 adjacent the handle 381. The first yoke arm 397 has athreaded hole 382 therethrough to receive the threaded end 380 of theadjusting screw 341, and the second yoke arm 398 has a larger hole 383to receive the shaft 399 of the adjusting screw 341. The shaft 399extends through the slit 333 in the neck 328 so that the neck 328 can befreely moved and pivoted to selectively position the shaft 399 withinthe slit 333 of the neck 32B.

The slit 333 is so defined by the neck 328 so that there is a narrowportion 384 and a broad portion 385 of the slit 333 forming a shelf 386within the slit 333. In the second preferred repair assembly 22, theadjusting and locking means 396 includes a spacer gripper 387 having acylindrical external portion 388 which fits through the second yoke arm398 larger hole 383 into the broad portion 385 of the slit 333, andteeth 371 at an end 372 of the cylinderical external portion 388 whichengage the shelf 386 within the slit 333. The spacer gripper 3B7additionally has a smaller hole 373 extending axially through the spacergripper 387 to receive the adjusting screw 341 shaft 399 in pivotalrelation so that the adjusting screw 341 may be turned, and an outwardlyfacing end 374 opposite the end 372 with teeth 371. The adjusting andlocking means 396 further includes the adjusting screw 341 handle 381,the flange 375 adjacent the handle 381, and the threaded end 380. Theflange 375 abuts against the outwardly facing end 374 of the spacergripper 387 so that turning the adjusting screw 341 in one directionmoves the flange 375 against the spacer gripper 387 to engage the teeth371 against the shelf 386 of the neck 328 and also to engage the neck328 between the spacer gripper 387 and the first yoke arm 397 in a fixedposition with relation to the suction cup base 321. Turning theadjusting screw 341 in an opposite direction disengages the teeth 371from the shelf 386 so that the neck 328 can freely move and rotate toselectively position the adjusting screw 341 shaft 399 within the slit333. The outwardly facing end 374 of the spacer gripper 387 includes anut portion 376 which has four abutment surfaces 377. The suction cupbase 321 has a wall 378 adjacent the second yoke arm 398. This wall 378abuts against one of the abutment surfaces 377 on the nut portion 376preventing the turning of the spacer gripper 387 when it is properlyseated in the second yoke arm 398 larger hole 383 and the broad portion385 of the slit 333. This provides additional assurance when the teeth371 of the spacer gripper 387 engage the shelf 386 that the neck 328will not pivot or move in relation to the suction cup base 321.

After the second preferred repair assembly 22 is secured on a windshield10 and the neck 328 pivoted and moved so that the circular opening 330directly overlies the windshield break area 18, the screw 38 should beinserted and tightened down so a seal is formed between the gasket 42and windshield 10. The lifting screw 392 in the small opening 391 of theleg 390 can be turned to lift the leg 390 away from the windshield 10 sothat the screw 38 in the circular opening 330 in the first section 329of the neck 328 is leveragedly forced down onto the windshield 10. Thisdownward leveraged force coupled with the downward force from tighteningthe screw 38 enables the gasket 42 to form a fluid-tight seal with thewindshield 10.

In repairing a windshield break with kit 1 or kit 2 according to thepresent invention, the repair assembly 22 is first positioned on thewindshield 10 so that the circular opening 30 of the neck 28 is directlyover the windshield break cavity 18 as shown in FIG. 2. The repairassembly 22 is then secured on the windshield 10 by pushing the clamp 36down parallel to the windshield 10, thereby outwardly pulling the arm 34connected to the suction cup 32 through the base opening which causesthe edges of the suction cup 32 to be forced down and adhere to thewindshield 10. The mirror 37 is then placed against the windshield 10 onthe side of the windshield opposite the repair assembly 22 so as toreflect the windshield break area and insure the repair assembly 22 islevel on the windshield surface and to monitor further stages of thewindshield repair. The mirror 37 can be secured on the windshield 10 bymeans of tape or by using the support frame 166 with the suction cups168, illustrated in FIG. 4.

Next the screw 38 is placed in the circular opening 30 of the neck 28 sothat the o-ring 42 or quad ring 142 is directly over the windshieldbreak area. The screw 38 is then turned to push the gasket, o-ring 42 orquad ring 142 down on the windshield to form a generally fluid-tightseal, which can be determined by looking at the reflection of thegasket, o-ring 42 or quad ring 142 in the mirror 37. The screw 38 mayalso have a tube 44 or tube 144 inserted in the screw cylindricalopening 40, as shown in FIG. 2.

When the first alternative repair assembly 22 illustrated in FIG. 5 isused, the repair assembly 22 is placed on the windshield 10 in alocation near the break area 10. The arm 234 is pushed until the air isexhausted from the suction cup 232 and the suction cup 232 adheres tothe windshield.

The first adjusting screw 237 is moved so that the neck 228 is rotatedaround the suction cup base 221 into approximate position with respectto the break area 18. Next the second adjusting screw 241 is moved so asto exactly line up the circular opening 230 in the neck 228 over thebreak area 18. The screw 38 is then placed in the circular opening 230and then turned until the gasket forms a tight seal on the windshield.

The second alternative repair assembly 22 illustrated in FIGS. 6 and 7is used in quite similar fashion as the first alternative repairassembly 22 in FIG. 5, except that the second alternative repairassembly is placed near the windshield break 18 so that the neck 328 isalready in approximate position with respect to the break area 18, andthe vacuum pump 395 arm 334 instead is used to exhaust air from thesuction cup 332. The adjusting screw 341 is then loosened and the neck328 moved and pivoted so that the circular opening 330 is exactly linedup over the windshield break 18. The screw 38 is then inserted in thecircular opening 330 and tightened onto the windshield 10. Additionally,with the second alternative repair assembly 22, it may be necessary toturn the lifting screw 392 in the leg 390 to leveragedly exert pressureon the gasket 42 in addition to that provided by turning the screw 38 inorder to form a tight seal on the windshield 10.

The next step is to fill the repair material applicator, such as thesyringe 48, with the repair material 46 and the needle 50 is attached tothe syringe 48. The needle 50 is inserted into the screw cylindricalopening 40 or, alternatively, into the tube 44 or tube 144, if such atube has been inserted in the screw cylindrical opening 40, and thesyringe plunger is depressed so as to transmit the repair material 46through the needle 50 to the surface of the windshield break area. Inplace of the syringe 46 and needle 50, a disposable plastic containerhaving a snoutlike dispenser could be used. If the plastic containerheld a premeasured amount of repair material 46, the snoutlike dispensercould simply be placed into the tube 44 or tube 144, and the containercould be squeezed so as to transmit repair material 46 to the surface ofthe windshield break area.

After injection of the repair material 46, the syringe 48 and needle 50are removed from the repair assembly 22. The next step is to attach in agenerally fluid-tight relation a vacuum pump 52 to the screw 38 or,alternatively, to the tube 44 by a hose 53 or other suitable connectingmeans; using equipment similar to that shown in FIG. 4 for kit 2, afluid-pressure pump 152 would be attached to the screw 38 or the tube144 by a hose 53 with fastening clips 180. The vacuum pump 52 or thefluid-pressure pump 152 is then operated so as to create a vacuum in therange of 10-20 inches of mercury over the windshield break area enclosedby the o-ring 42 or quad ring 142, as measured by the gauge 56 attachedto the vacuum pump 52 or the gauge 156 attached to the fluid-pressurepump 152, for about 3-7 minutes or until air bubbles cease appearing inthe mirror's reflection of the crack area, signifying initial exhaustionof air from the crack. Next the vacuum is increased to within the rangeof 15-25 inches of mercury by means of the vacuum pump 52 and maintainedfor about 3-7 minutes or until air bubbles cease appearing in themirror's reflection of the crack area, signifying secondary exhaustionof air from the crack. In the final vacuum stage necessary to force airout of the windshield break cavity 18, the vacuum is further increasedto within the range of 20-30 inches of mercury and maintained for about3-7 minutes, or until air bubbles cease appearing in the mirror'sreflection of the crack area, signifying final exhaustion of air fromthe crack, after which time the vacuum pump 52 is disengaged from therepair assembly 22. If a fluid-pressure pump is used, the pump 152remains attached to the repair assembly

Alternatively, a vacuum in the range of 20-30 inches of mercury could becreated over the windshield break area and maintained until air bubblescease appearing in the mirrored reflection of the windshield break area,signifying the end of air exhaustion from the windshield crack.

The next step is to create a positive pressure over the windshield breakarea so as to drive the repair material 46 into the cavity 18. To thisend, the positive pressure applicators whether in the form of a pressuresyringe 56, air pump, or fluid-pressure pump 152, is engaged in agenerally fluid-tight relation in the screw cylindrical opening 40 or,alternatively, in the tube 44 or tube 144. If the positive pressureapplicator is a pressure syringe, the pressure syringe plunger is thendepressed to a level at which the notched handle 58 engages the notch inthe clip 60. If the positive pressure applicator is an air pump or afluid-pressure pump, pressure is applied to the desired level. In mostcases, the desired level will be within the range of 40-50 pounds persquare inch, easily measured on a gauge 154 of a fluid-pressure pump152. In any case, the pressure is maintained for about 3-10 minutes,after which time the repair assembly is removed from the windshield byraising the clamp 36, thereby releasing the suction cup 32.

Many repair materials will harden within the windshield break withoutfurther processing. Some repair materials, however, especially certainpolymers, must be provided with ultraviolet light to initiate acatalyzed hardening reaction. In those cases, the final repair step isto provide ultraviolet light to the windshield break area for about oneminute with the ultraviolet light source 62 so as to cause the repairmaterial 46 to harden within the windshield cavity 18.

EXAMPLE 1

According to the present invention, the repair assembly was positionedand secured on the windshield so that the circular opening of the neckwas directly over the windshield break. The mirror was then placedagainst the windshield on the side of the windshield opposite the repairassembly and secured on the windshield with tape.

The screw, with a tube inserted in it, was then placed in the neck withthe o-ring directly over the windshield break area. The screw was turnedso as to drive the o-ring down on the windshield to form a generallyfluid-tight seal; progress of the seal formation was monitored bywatching the reflection of the screw and o-ring area in the mirror.

Next the syringe was filled with a polymeric repair material, and theneedle was attached to the syringe. The needle was inserted through thetube in the screw and the syringe handle was depressed so as to transferpolymer from the syringe to the windshield break area.

The syringe and needle were then removed from the tube. A hose waspositioned with one end attached to the tube in a generally fluid-tightrelation and the other end attached to the vacuum pump in a similar,generally airtight fashion. A vacuum of 15 inches of mercury was exertedon the windshield break area and maintained for 5 minutes. Then thevacuum was increased to 20 inches of mercury and maintained for 5minutes. Finally, the vacuum was further increased to 25 inches ofmercury and maintained for 5 minutes.

The hose and vacuum pump were then removed, and the positive pressureapplicator in the form of pressure syringe was inserted into the tube ina substantially fluid-tight relation. The pressure syringe handle wasdepressed, thereby exerting positive pressure on the windshield breakarea, until the notch in the handle engaged the clip. The pressuresyringe was left in that position for 5 minutes.

The polymer used as the repair material required ultraviolet lightbefore it would harden in the windshield crack. Therefore, in the nextstep, the repair assembly was removed from the windshield and theultraviolet light source was used to supply heat to the windshield breakarea for 1 minute.

Many repair materials are suitable for use in the present invention.Generally the repair material chosen must have a viscosity low enough toallow the repair material to flow into the windshield break cavity andmust cure rapidly to substantially the refractive index of windshieldglass, with or without heating. Typical repair materials which may beused are resins and polymers. Examples of polymers which may be usedinclude polyester, epoxy and urethane. Other suitable repair materialsare described in the prior art.

A series of carefully measured and maintained vacuum steps prior toapplying positive pressure to the windshield break area distinguish thepresent invention. Also, the prior art does not disclose the use of ahand-operated, unitary fluid pressure pump to apply both negative andpositive pressures to the windshield break area. In addition, the priorart does not teach the use of a mirror to monitor seal formation and todetermine the end of each stage of air exhaustion from the crack,thereby insuring complete filling of the windshield crack with repairmaterial. There is no need to outgas the repair material prior toinjection in order to permit a stronger vacuum.

Finally, the kit and its contents are reusable for repairing manywindshield breaks.

It is to be understood that the present invention is not limited to theparticular construction and arrangement of parts disclosed andillustrated herein but embraces all such modified forms thereof whichare within the scope of the following claims.

What is claimed is:
 1. A repair assembly for use in repairing windshieldbreaks, comprising:(a) a suction cup base; (b) a neck having a firstsection with a circular opening, and also having a second section formedat an angle to the first section which second section has a lengthwiseslit; (c) means for pivotally connecting the neck to the suction cupbase through the lengthwise slit of the second section of the neck; (d)means for adjusting and locking the position of the neck in relationshipto the suction cup base; and (e) a screw having a lengthwise cylindricalopening and adapted to be positioned in the circular opening of thefirst section of the neck, wherein the suction cup base may be attachedto a windshield near a windshield break and the screw may be positionedover the windshield break and substantially perpendicular to thewindshield by selective moving and pivoting of the neck and selectiveadjustment and locking of the adjusting and locking means.
 2. The repairassembly specified in claim 1 wherein the suction cup base has first andsecond yoke arms extending therefrom to hold the pivotal connectingmeans, and the adjusting and locking means.
 3. The repair assemblyspecified in claim 2 wherein the pivotal connecting means comprises ashaft of an adjusting screw which has in addition to the shaft, athreaded end, a handle, and a flange adjacent the handle, and whereinthe first yoke arm has a threaded hole therethrough to receive thethreaded end of the adjusting screw and the second yoke arm has a largerhole to receive the shaft of the adjusting screw, the shaft extendingthrough the slit in the neck so that the neck may be freely moved andpivoted to selectively position the adjusting screw shaft within theslit of the neck.
 4. The repair assembly specified in claim 3 wherein(a)the neck defines a slit having a narrow portion and a broad portion toform a shelf; (b) the adjusting and locking means includes a spacergripper with(i) a cylindrical external portion which fits through thesecond yoke arm larger hole into the broad portion of the slit, (ii)teeth at an end of the cylindrical external portion which engage theshelf within the neck, (iii) a smaller hole extending axially throughthe spacer gripper to receive the adjusting screw shaft in pivotalrelation, and (iv) an outwardly facing end opposite the end with teeth;and (c) wherein the adjusting and locking means further includes theadjusting screw handle, the flange adjacent the handle, and the threadedend, the flange abutting the outwardly facing end of the spacer gripperso that turning the adjusting screw in one direction moves the flangeagainst the spacer gripper to engage the teeth against the shelf of theneck to hold the neck between the spacer gripper and the first yoke armin fixed position with relation to the suction cup base, and turning theadjusting screw in an opposite direction disengages the teeth from theshelf so that the neck may freely move and rotate to selectivelyposition the adjusting screw shaft within the slit.
 5. The repairassembly specified in claim 4 wherein the outwardly facing end of thespacer gripper comprises a nut portion which has at least one abutmentsurface, and wherein the suction cup base has a wall adjacent the secondyoke arm, the base wall abutting the abutment surface of the spacergripper to prevent rotation of the spacer gripper when the handle andadjusting screw flange are rotated.
 6. The repair assembly specified inclaim 1 wherein the suction cup base comprises:(a) a base having aplurality of openings; (b) a suction cup which is attached to a bottomside of the base; and (c) a vacuum pump attached to the suction cup andprojecting out through a sideways opening of the base, which vacuum pumphas an arm adapted to be movable inwardly and outwardly from the base soas to exhaust air out from the suction cup, thereby forcing the edges ofthe suction cup to adhere to the windshield.
 7. The repair assemblyspecified in claim 1 further comprising:(a) a gasket attached to the endof the screw next to the windshield and adapted to form a generallyfluid-tight seal with the windshield when the screw is tightened down onthe windshield; and (b) a tube adapted to be inserted in the end of thescrew cylindrical opening opposite the gasket so as to guide insertionof the repair material applicator.
 8. The repair assembly specified inclaim 1 wherein the suction cup base includes a leg which extendssidewardly in a direction opposite the neck and the leg has a smallopening to receive a lifting screw, and the repair assembly furtherincludes a lifting screw inserted in the small opening, which liftingscrew turns to lift the leg away from the windshield so that the screwin the circular opening in the first section of the neck is forced downonto the windshield break when the repair assembly is secured on awindshield.
 9. A repair assembly for use in repairing windshield breaks,comprising:(a) a suction cup base; (b) a neck having a first sectionwith a circular opening, and also having a second section formed at anangle to the first section which second section has a lengthwise slit;(c) a first pivotal connector which is located on top of the suction cupbase and connects the suction cup base to the lengthwise slit of thesecond section of the neck; (d) a first adjusting means which can bemoved so as to allow the neck to rotate around the suction cup base bymeans of the first pivotal connection; (e) a second pivotal connectorwhich extends out from the first pivotal connector through thelengthwise slit of the second section of the neck; (f) a secondadjusting means which can be moved so as to allow the second pivotalconnector to move the length of the lengthwise slit, and also to allowthe neck to pivot around the second pivotal connector; and (g) a screwhaving a lengthwise cylindrical opening and adapted to be positioned inthe circular opening of the neck first section, wherein the suction cupbase may be attached to a windshield near a windshield break and thescrew may be positioned over the windshield break and substantiallyperpendicular to the windshield by selective rotation and pivoting ofthe neck and selective adjustment and locking of the first adjustingmeans and the second adjusting means.
 10. The repair assembly of claim 1wherein the suction cup base comprises:(a) a base having a plurality ofopenings; (b) a suction cup which is attached to the side of the baseopposite the first pivotal connector, which suction cup has at least onehandle for ease in removing the repair assembly from the surface of thewindshield; (c) an arm attached to the suction cup and projecting outthrough a sideways opening of the base, which arm is adapted to bemovable in and out from the base so as to exhaust air out from thesuction cup, thereby forcing the edges of the suction cup to adhere tothe windshield.
 11. The repair assembly of claim 1, furthercomprising:(a) a gasket attached to the end of the screw next to thewindshield and adapted to form a generally fluid-tight seal with thewindshield when the screw is tightened down on the windshield; and (b) atube adapted to be inserted in the end of the screw cylindrical openingopposite the gasket so as to guide insertion of the repair materialapplicator.